Forming Thin Copper Sheets into a Mold
Forming Thin Copper Sheets into a Mold
(OP)
I'm trying to get a thin copper sheet approx. .004 thickness to stay in a mold so that I can pour silicone into the copper and form it into the shape I want. Problem is that the copper wants to spring up out of the mold. Has anyone used a process that would help me out in this situation? The copper sheet is approx. 6" wide but the width of the mold is 2.4" or so. In the attached picture is the cross section of the mold, roughly. Both of the radii are a controlled dimension that the copper would have to form to tightly. All thoughts and questions are appreciated.
thanks!
thanks!





RE: Forming Thin Copper Sheets into a Mold
RE: Forming Thin Copper Sheets into a Mold
RE: Forming Thin Copper Sheets into a Mold
RE: Forming Thin Copper Sheets into a Mold
I remember using tooling holes in the work, (2)holes across length wise, nest the the parts with tooling pins in the
die, this will prevent the stock from moving.
the pins should clear the mating die.
good luck
RE: Forming Thin Copper Sheets into a Mold
Two alternatives come to mind:
1. Tig weld two blanks together and inflate them between two molds. Hydraulic fluid is safer than air, and you may need more pressure than you can easily get in air. The liquid also gives you better control over the strain rate.
2. Repousse.
Mike Halloran
Pembroke Pines, FL, USA
RE: Forming Thin Copper Sheets into a Mold
Start with a shallow draw of thicker copper, then spin it in a lathe and iron it down over a wooden plug. You can reduce the wall thickness as you iron it down. Just like metal spinning, more plastic deformation.
Skill intensive, but not so much as repousse.
Mike Halloran
Pembroke Pines, FL, USA
RE: Forming Thin Copper Sheets into a Mold
The have adhesive backed copper tape in various sizes.
What about contact cement/spray adhesive?
RE: Forming Thin Copper Sheets into a Mold
I saw some posts that about drawing the copper. I am not going to be drawing it in, it comes in pre-cut sheets, what I need is to find a way to form it to the walls of the mold so that I don't have to mold the silicone then wrap the copper around it manually, I'm trying to do it all in one process. The tape ideas might work, however this copper comes with a phenolic primer on it, and I'd have to see how the adhesive works with that material.
RE: Forming Thin Copper Sheets into a Mold
RE: Forming Thin Copper Sheets into a Mold
How long is this pipe?
Mike Halloran
Pembroke Pines, FL, USA
RE: Forming Thin Copper Sheets into a Mold
To MikeHallroan, for the actual production size this will be about 10' (ft) long. Right now I'm trying to do samples about 1'-2' long.
RE: Forming Thin Copper Sheets into a Mold
I use form these type of parts with no issues.
the other way is to pinch the outer edges with an outer die , then the inner die punches the center.
need to clamp this thing so it doesn't move.
the tooling holes is the other way.